Chevrolets 1996 C1500 pickups offer two all-new features. The trucks have a powerful family of Vortec engines under the hood and a third door, which provides unprecedented access to the Extended Cab. |
It didn’t take long for sparks to start flying around our project truck. Bell Tech’s 4/6 drop, Budnik Tusk II wheels, and BFGoodrich Comp T/A tires were installed at Trader&8217s Truck Accessories. |
Phase I made a dramatic difference in the truck&8217s appearance. A lowered stance and flashy wheels are typically the first modifications made to a custom truck. |
Lowering our truck 4/6 required Bell Tech 2500 series 2-inch dropped spindles, 4450 2-inch dropped coil springs, 6607 6-inch flip kit, and shocks. The kit comes complete with Nitro-Drop shocks and all the hardware necessary for installation. |
The stock coil spring (left) is 20 percent taller than the new spring. Although the new spring has a shorter stance, its rate, at 1,100 pounds, is significantly greater than the stock. |
The pin on the Bell Tech spindle (right) sits 2 inches higher than the stock location. The new spindle is designed to maintain the stock spindle&8217s geometry. This reduces premature wear on the ball joints and tie-rod ends. |
Before installing the new spindle, disassemble the shocks, the brake calipers, the drums, the control arms, and the tie rods. Also, notch the upper control arms so the truck can be aligned after installation. |
After putting the new coils and shocks in place, you can install the spindle. Be sure to inspect all the joints and the bushings and replace them if they&8217re worn out. |
Remove all the brackets, bolts, and lines from the area near the intended C-section. |
The flip kit comes with a paper template to guide the C-section cut. Trader&8217s does so many of these installations that it supplies its technicians with steel templates. With the template in place, remove a section of the frame. |
You can make the cut with a variety of cutting tools. Our C-notch cut exhibits the precision of a plasma cutter. |
Slide the sleeve over the cut in the frame. Notice that the framerail has been cut just enough to squeeze the sleeve into position. |
Before assembling the rear, trim the framerails above the differential and the carrier bearing. Spray the cuts with paint to protect against corrosion. |
Install a variety of shims and spacers to correct the driveshaft geometry, which includes the carrier bearing, the rear axle, and the transmission. |
Aligning the driveshaft in this manner eliminates unwanted vibration and wear. |
Reassemble the rear axle and suspension with the kit&8217s U-bolts and brackets. To achieve the drop, relocate the axle above instead of below the leaf springs. Bell Tech shocks are specifically designed for lowered suspensions. Bolt the shocks to a new shock bracket. |
Slim urethane bushings replace the chunky stock bumpstops. Install the new bushings in the front and the rear. |
Cutting any new truck is cause for nervousness. Mark the truck with a marker before making any cuts. Pictured on the left are the pieces of the frame that are removed for the C-section. The pieces on the right are the parts of the framerail that are cut to accommodate the differential and the driveshaft. |
Dropping the truck 6 inches in the rear significantly reduces the gap between the fender and the tire. Compare the spacing show here (before) with the look in the photo below (after). |
The BFGoodrich Comp T/A tires and the Budnik wheels also enhance the truck&8217s custom persona. |
The Budnik Tusk II wheels measure 16x7 in front and 16x8 in the rear. Fitment is achieved with 4.5 inches of backspacing on the front wheels and 5 inches on the rear. |
The BFGoodrich Comp T/A tires feature a directional tread pattern. This translates into increased traction on wet and dry surfaces. |
With the first phase of modifications complete, we’ll next begin working under the hood. |
A stock pickup truck in the hands of a sport truck builder offers a whole universe of performance and cosmetic modification possibilities. When that pickup is a three-door '96 Chevy C1500 powered by the all-new Vortec 5000 engine, the confines of that universe are expanded to a whole other dimension. It's no secret that the aftermarket produces more components for fullsize Chevys than everyone else combined. You could spend a year compiling a list of the aftermarket wheels alone.
Fully aware of that potential, we greeted the Chevy, Sport Truck's latest project truck, with all the enthusiasm of the most ardent street truck devotees. Our plan is to modify the stock truck into a custom cruiser with a variety of suspension, wheel and tire, interior, engine, and body bolt-on components. In a series of monthly installments, we hope to transform the truck in the pages of the magazine. In keeping with the truck's daily driver theme, we'll utilize components that enhance and maintain the Chevy's driveability and functionality.
Phase I - Suspension, Wheels, And Tires
The type of suspension and its subsequent drop has a direct impact on the tire and wheel sizes. Recognizing that these three components share a symbiotic relationship, we were careful to choose sizes that wouldn’t create fitment problems or have a negative impact on the truck’s ride quality. We opted for a classic Bell Tech 4/6 drop and 16-inch Budnik wheels wrapped with Z-rated BFGoodrich Comp T/A tires.
The frontend was lowered 4 inches with Bell Tech's 2500-series front spindles and 4450 coil springs. The frame was C-notched in the rear to accommodate Bell Tech's 6607 flip kit and a pair of re-arched springs. That combination resulted in a rear 6-inch drop for our Chevy.
Since extended-cab trucks are notorious for having vibration-related problems after being lowered, we installed the kit's rear axle pinion shims, carrier bearing spacer plate, and transmission spacers. These components are designed to improve driveline geometry and eliminate any associated vibrations.
The kit can also be upgraded with Bell Tech's AirJack system should our load-carrying or towing needs require airbags. We didn't opt for installation at this time, but the unit can be bolted right to the existing kit without further modifications.
All the suspension work was completed in less than six hours. The quick transformation was due to two factors: precision components and our mechanic Miguel Ruiz, who has been lowering trucks at Trader's Truck Accessories for nearly 10 years. The kit requires very little modification to the truck and absolutely no "unexpected" fabrication. The frame, framerails, and lower control arms did require cutting. Thankfully, Ruiz made the cuts as close as possible so as not to compromise the truck's structural integrity. This was particularly important on the framerail that crosses over the C-sections. A wide cut in this area would defeat the rail's purpose.
Wheels And Tires
The new suspension configuration created enough room for front 16x7 Budnik Tusk II wheels (4-1/2-inch backspacing) and rear 16x8s (5-inch backspacing). The billet aluminum wheels are substantially lighter than stock, and their contemporary design sets the tone for the rest of the Chevy’s appearance.
We applied the Plus One, Plus Two fitment principle to the truck's new tires. The principle simply matches the aspect ratio of the tires to the wheel size while maintaining the overall diameter of the tire. In our case, we didn't want to exceed an overall tire height of 26 inches. The Budnik wheels are an inch larger than stock, but their increased size is literally absorbed by the sidewalls of our 255/50R16 (front) and 245/50R16 (rear) tires.
The BFGoodrich Comp T/A ZR tires feature a directional, dual-compound tread, two steel belts, and a solid center rib. Its ZR rating means it can travel at speeds over 149 mph. The Comp T/As are designed for maximum wet and dry handling, excellent ride comfort, low noise, and long tread life.
Track Test
Prior to any suspension, wheel, and tire modifications, our 1996 Chevy Extended-Cab Sportside pickup truck was tested at Los Angeles County Raceway. The track test gave us valuable insight into the truck’s stock performance and provided baseline performance numbers to compare further modifications against.
The truck is equipped with two new-for-1996 features. The Three-Door Access System provides upgraded entrance to the truck's interior Extended Cab. The third door allows passengers to pass freely from the rear bench seat and increases the cargo space behind the front seats.
The truck also features Chevrolet's new Vortec-series engine. Our 5.0L V-8 produces 230 hp at 4,600 rpm and 285 lb-ft of torque at 2,800 rpm, according to the manufacturer. Our track tests revealed an 18.05-second quarter-mile at 75.81 mph (uncorrected).
In addition to the new features, the teal green metallic pickup came equipped with a number of factory options. Six-way-power high-back seats, an AM/FM/cassette stereo, cast-aluminum wheels, Silverado trim, and four-speed automatic transmission with overdrive were among the upgraded items delivered from Chevrolet.
The MSRP totalled $24,564 including the total model, options, and destination charges.
Phase II
With the running gear in place, we’ll direct our attention under the hood in the next installment. Engine and exhaust modifications will consume most of the coverage. The story will also report on a chip, pulleys, and a free-flowing air filter package. Once the work is complete, we’ll compare the truck’s performance against stock baseline numbers.